Floor beam assembly and welding technology

Contents

Table of contents

Introduction

1 PROCESS PART

1.1 Characteristics and analysis of the operating conditions of the floor beam

1.2 Selection and justification of assembly and welding methods

1.3 Strength calculations of beam structure

1.3.1 Determination of bearing capacity of welded beam

1.3.2 Calculation of beam support unit

1.3.3 Calculation of beam element joints

1.4 Selection of equipment for semi-automatic welding in Ar CO

1.5 Selection of equipment for automatic welding under flux

1.6 Preparation of edges for welding

1.7 Welding Mode Calculations

1.7.1 Calculation of semiautomatic welding modes in ArCO

1.7.2 Calculation of automatic welding modes under flux layer

1.7.3 Calculation of welding materials and electric power requirements

1.8 Measures to combat welding stresses and strains

1.9 Quality control of welds

2 DESIGN PART

2.1 Auxiliary assembly and welding equipment

2.2 Layout of equipment placement in sections

3 Organizational and economic part

3.1 Design cost calculation

3.1.1 Material Cost Calculation

3.1.2 Calculation of process power cost

3.1.3 Calculation of basic wages of production workers

3.1.4 Calculation of additional wages and social contributions

3.1.5 Calculation of depreciation charges

3.1.6 Overhead expense

3.1.7 Calculation of unit cost

3.2 Calculation of wholesale and selling price of the enterprise for the product

3.2.1 Calculation of wholesale price of the enterprise

3.2.2 Calculation of the selling price of the enterprise

3.3 Calculation of main economic indicators of production and sale of products

3.3.1 Calculation of annual production volume

3.3.2 Calculation of sales revenue and cost of annual output

3.3.3 Calculation of profit and profitability

3.4 Calculation of capital investment efficiency

4 Safety of works during assembly and welding of floor beam 12m

4.1 Safety of Automatic Flux Welding Process

4.2 Analysis of possible hazardous and harmful production factors of the automatic flux welding process

Measures taken to reduce the concentration of harmful substances in the workplace

4.3 Calculation of exhaust ventilation system

Conclusion

Paper

Explanatory note contains: p.82, Fig.21, Table 19.

Keywords: Automatic welding under flux, Building structures, Double beam, Strength, Welding process, Process equipment, Welding equipment.

The purpose of the diploma project: this project describes the technology and calculation of the I-beam slab, the choice of the welding method, welding equipment, welding materials, power supply and welding equipment, the rationing of operations, the determination of the processability of the structure and the cost effectiveness of its manufacture, as well as the plan of the section for the manufacture of this slab beam .

The main task of the degree project - to achieve quality products and also to organize necessary conditions for increase in efficiency of work, use of the latest equipment, reduction of a consumption of raw materials, materials, energy.

Having made calculations, the selling price of the structure is 39138.97 rubles. The calculation of economic, main indicators showed that production is profitable and net profit is equal to 281998.4 rubles. The cost-effectiveness ratio is 10.15%, which means that the project is efficient.

Introduction

The metal beam of the I-beam floor is quite often used in construction and other industries. For the duration of operation, it is subject to frequent dynamic and static load mainly on bending. As a result, defects may appear that will lead to destruction.

Due to these factors, it is necessary to improve the quality of welding. Welding is a time-consuming process requiring some attention.

To increase the productivity and most importantly the quality of welded structures, flux welding is used. This method increases the productivity and quality of welds.

The design object is the technology of manufacturing a floor beam 12 m.

Subject of design - improvement of functional properties of the floor beam.

The purpose of the project is to develop a technology for assembling-welding a floor beam 12m.

To improve the quality of the design, you need to solve the following problems:

Make a design analysis and also choose cost-effective welding methods, based on information analysis, calculate the theoretical prerequisites for improving EMF, justify the use of semi-automatic welding.

Select the means for technological equipment and implementation of the new welding technology, planning solutions when designing the welding section.

Calculate current and one-time costs when implementing the new technology and identify its advantages according to the criteria of technical and economic efficiency.

Prepare safe operation rules and conditions.

Safety of works during assembly and welding of slab beam 12m

4.1 Safety of the process of automatic welding under flux.

Automatic flux welding requires special safety regulations. The provided rules are in GOST 12.3.00386 - Occupational Safety Standards System. Electric welding works. Safety requirements. During operation, the welder is affected by a number of hazardous and harmful factors.

4.2 Analysis of possible hazardous and harmful production factors of the automatic flux welding process.

Hazards during the automatic flux welding process:

uncovered parts of equipment with high temperature can cause burns, as well as failure of production equipment;

the content of fine contaminants in the air and the exceeded level of smoke at the workplace;

high levels of infrared and ultraviolet radiation;

High voltage in the electrical circuit supplied to welding equipment or short circuit that can occur through the human body;

Danger of electric shock during welding operations. The main causes of electric shock are:

- non-compliance with the rules of technical operation of welding equipment;

- touching current supply parts of welding equipment or to the housing energized due to failure of insulation of equipment or grounding devices;

The effect of current depends on many factors: on the genus (constant or alternating); at alternating current - from frequency; current (or voltage), current flow time, current path through the body, generally depends on the physical and mental state of the person.

The most dangerous for a person is an alternating current with a frequency of 50... 500 Hz. In order to avoid the danger of electric shock, welding operations must be performed in accordance with the requirements of GOST 12.1.03081 2001. SSBT Electrical safety, protective grounding, suspension.

To ensure the safety of welding work, personal eye protection equipment is used. General technical requirements GOST R12.4.2342007 SSBT. Special clothing for protection against thermal hazards of electric arc. General technical requirements and test methods, GOST 12.4.12483 SSBT.

Another harmful effect to which workers are exposed is air pollution in the premises where work is carried out.

Due to the high temperature of the welding arc, the metal boils and its vapors rise, condense and oxidize with air oxygen, as a result, very thin dust of metal oxides is formed, as a result of which airway damage occurs.

In addition to metal dust, gases emitted during the melting of flux and charge enter the air.

The area where the welding charge is produced and the flux already used is ground is equipped with local exhaust and plenum ventilation. Local ventilation is installed so that to bring to the furnace, mixer, mills according to SNiP 41012003 Heating, ventilation and conditioning.

Air in the working area of the welder operator complies with GOST 12.1.00588. General sanitary and hygienic requirements for the working area air.

The welding arc is a very powerful light source with different wavelengths that affect the welder's vision to varying degrees.

Radiation occurs in the infrared, ultraviolet and visible light range.

With long-term infrared radiation (760 nm), complete loss of vision occurs.

Ultraviolet rays, even with relatively short radiation, cause eye disease.

Welders are provided with:

- special protective clothing according to the requirements of GOST 12.4.12683 SSBT. Fabrics and materials for workwear welders. Method for determination of resistance to ultraviolet radiation. GOST 12.4.2172001 - SSBT. Personal protective equipment against radioactive substances and ionizing radiation. Requirements and test methods

- canopy hoses in accordance with GOST 12.4.01075. Personal protective equipment. The sleeves are special. Specifications.

- special shoes for welding works according to GOST 12.4.10383. Special protective clothing, personal protective equipment for hands and legs. Classification.

GOST R 12.4.2372007 SSBT. The clothes are special. Methods of testing the material when exposed to splashes of molten metal. GOST R 12.4.230.12007 SSBT. Personal eye protection equipment. General technical requirements. GOST 12.4.02384 * SSBT. Protective facial shields. General technical requirements and control methods.

All light filters make of special CC14 glass depending on specific features of sight. Light filters do not pass ultraviolet rays at all, and infrared rays pass only in the range from 0.1... 4 %.

According to SNiP 2.09.0285 Building codes and regulations. Industrial buildings, welding and surfacing section, it produces thick-walled products, belongs to the category of G-room with non-combustible substances and materials in a hot, hot or molten state.

For fire safety, welding is carried out in accordance with the requirements of SNiP 210197 Fire safety of buildings and structures. In the area where welding works are carried out, there are fire fighting equipment and equipment in accordance with the requirements of NPB 11003 Composition of buildings, structures, premises and equipment requiring protection by automatic fire extinguishing units and automatic fire alarm.

Installation of the plant is carried out in accordance with the safety rules for installation works operating at the enterprise and approved by the chief engineer of the enterprise and GOST 12.1.01378 Construction. Electrical safety. General requirements .

Installation operation in general is carried out according to "Interindustry rules on labor protection (safety rule) at operation of the RD 15334.0-03.150-00 P M0162001 SWEAT electroinstallations.

Production equipment has built-in device for removal of harmful substances released during operation directly from the place of their formation and accumulation GOST 12.2.00391 Occupational safety standards system. Production equipment. General safety requirements.

Measures taken to reduce the concentration of harmful substances in the workplace

It is necessary to calculate the exhaust ventilation system to ensure a safe concentration of substances harmful to the welder.,

Conclusion

As a result of the design of the diploma project, the floor beam of twelve meters was analyzed, of all the welding methods: the most modern methods of metal application were chosen, the assembly and welding technology was developed, and the quality control method was also chosen.

Assembly equipment is selected: rotary cantilever, assembly table, conductor, tilter.

Electrode wire is supplied by means of semi-automatic with rotary cantilever, as well as by means of tractor. Flux is supplied using the ADF250 tractor, which increases the quality and productivity of welding. A choice was made: welding materials, welding methods, welding modes, welding equipment, a sequence of operations was made, the reliability of the beam was evaluated, as well as the economic efficiency of its production, a site plan for the production of this welding floor beam was also designed.

Safety issues in this production were analyzed. Calculations were made for the exhaust ventilation system. Issues on labor protection were also considered.

Calculations were made on technical and economic indicators. As a result, net profit is 281998.4 rubles. Sales profitability 15%. Cost-effectiveness ratio 10.15%.